Guide

Print on Demand vs Bulk Ordering: Which Is Better in 2026?

Updated February 2026 · 8 min read

Whether you're starting a t-shirt business, creating merch for your brand, or just want custom tees for an event — you have two main options: print on demand (POD) or bulk ordering. Here's how they compare.

Print on Demand (POD)

With POD, each item is printed only when someone orders it. No inventory, no minimum orders, no upfront costs.

Pros

• Zero upfront cost — no inventory risk
• No minimums — sell 1 or 1,000
• Unlimited designs — test freely
• Automated fulfillment — print partner handles everything
• AI integration — generate unique designs on the fly

Cons

• Higher per-unit cost ($8-15 per tee)
• Longer shipping (3-7 business days production)
• Less control over quality inspection

Bulk Ordering

You order a set quantity upfront (usually 50+ minimum) with screenprinting or DTG.

Pros

• Lower per-unit cost ($3-8 per tee at scale)
• Faster fulfillment once you have inventory
• Quality control — inspect before shipping

Cons

• High upfront cost ($500-5,000+)
• Inventory risk — unsold stock
• Limited designs (expensive to change)
• Storage and logistics overhead

Cost Comparison

When to Use Each

Choose POD when:

• Testing new designs or markets
• Running a small brand or side hustle
• Offering personalized/custom products
• You want zero risk

Choose bulk when:

• You have a proven best-seller
• Ordering 500+ of the same design
• Events or corporate orders
• Maximum profit margins are priority

The AI Advantage

In 2026, AI has made POD even more powerful. Platforms like Shirtgen.ai let you generate unlimited unique designs instantly — something impossible with bulk ordering. Each customer can get a truly one-of-a-kind design.

This is the future: AI generation + POD fulfillment = infinite catalog, zero inventory.

Try creating an AI design for free →